Solar cell panel and the method for manufacturing the same

ABSTRACT

According to an aspect of an embodiment of the present disclosure, there is provided a solar cell panel and a method for manufacturing the same. The solar cell panel comprises: a solar cell for generating electric power from sunlight; a coverglass for covering the solar cell; transparent shims, which are disposed between the solar cell and the coverglass at the points where the distance between the solar cell and the coverglass needs to be controlled, and form a space between the solar cell and the coverglass; and adhesive layer, which fills the space between the solar cell and the coverglass and has the thickness the same as that of the transparent shims.

GOVERNMENT RIGHTS

This invention was made with government support under a subcontract withJohns Hopkins University, Applied Physics Laboratory, under NASA PrimeContract NN06AA01C. The Government has certain rights in the invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a solar cell panel with coverglassadhesive which has controlled thickness, and a method for manufacturingthe solar cell panel.

2. Description of the Related Art

In the prior art, a solar cell panel normally comprises solar cells forgenerating power from solar radiation, a coverglass for opticalfiltering and protecting the solar cells from external influences, suchas radiation, air, dust or water, and adhesive layer for binding thecoverglass to the solar cell and forming air-tight/liquid-tight sealtherebetween. The term “panel” as used herein refers to any type ofsupporting or mounting member, whether flexible or rigid. In the usageof those in the field of solar cell panel design and fabrication, somemay refer to a “panel” as a “substrate.” However, such usage should bedistinguished from the usage of “substrate” in the semiconductor fieldin which “substrate” usually refers to bilk semiconductor material.Optionally, the solar cell panel has other components, such as acontroller for controlling the interconnection of groups of solar cells,a accumulator or power distribution hub for accumulating the poweroutput from the individual or groups of solar cells, or a honeycombmember for supporting and strengthening the structure. The solar cellcomprises thin-film semiconductor device with electrical terminals onthe front and/or back side of the semiconductor substrate. Optionally, aplurality of solar cells can be disposed and interconnected as an arrayvia wire and diodes, such that the area and the output voltage of thesolar cell panel can be enlarged.

In prior art, when attaching the coverglass to the solar cell, opaquemechanical shims are used to support the coverglass on the solar cell,and then the adhesive layer is disposed between the solar cell and thecoverglass, such that the thickness of the adhesive layer is determinedby the opaque shims.

However, after the adhesive is cured, the opaque shims have to beremoved. The disadvantages of this technique are that (a) removing theopaque shims was tedious and time consuming, and required back-fillingthe voids with fresh adhesive; (b) removing the opaque shims wasmechanically disruptive and often damaged the solar cell panels bycracking the corners, resulting in scrapping those parts.

Thus, a solar cell panel and the method for manufacturing such solarcell panel, which can overcome the above disadvantages, are needed inthe art.

SUMMARY

According to an aspect of an embodiment of the present disclosure, thereis provided a solar cell panel, comprising: a solar cell for generatingelectric power from sunlight; a coverglass for covering the solar cell;transparent shims, which are disposed between the solar cell and thecoverglass at the points where the distance between the solar cell andthe coverglass needs to be controlled, and form a space between thesolar cell and the coverglass; and adhesive layer, which fills the spacebetween the solar cell and the coverglass and has the thickness the sameas that of the transparent shims.

According to another aspect of an embodiment of the present disclosure,there is provided method for manufacturing a solar cell panel,comprising the steps of: preparing transparent shims with predeterminedthickness; placing the transparent shims on the solar cell forgenerating electric power from sunlight or a coverglass for covering thesolar cell, at the points where the distance between the solar cell andthe coverglass needs to be controlled; dispensing adhesive onto thesolar cell or the coverglass; combining the solar cell and thecoverglass, such that in the combined panel, the transparent shims andthe adhesive is sandwiched between the solar cell and the coverglass andthe thickness of the adhesive is the same as that of the transparentshims; and curing the adhesive.

By using the transparent shims, the transparent adhesive layer of thecontrolled thickness can be attained in one processing step, and it isnot necessary to remove the transparent shims after the adhesive iscured, thereby facilitating the manufacturing of the solar cell panel.

Further aspects, features and advantages of the present invention willbe understood from the following description with reference to thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the invention and,together with the description, serve to explain the principles of theinvention.

FIG. 1 is a simplified exploded view schematically illustrating a solarcell panel according to an embodiment of the present disclosure, inwhich the adhesive layer is omitted for clarity.

FIG. 2 is a simplified perspective view schematically illustrating asolar cell panel according to an embodiment of the present disclosure,in which the adhesive layer is omitted for clarity.

FIG. 3 is a simplified top view schematically illustrating the positionof the transparent shims relative to the solar cell panel according toan embodiment of the present disclosure.

FIG. 4 is an exemplary flow chart of method for manufacturing the solarcell panel according to an embodiment of the present disclosure.

FIG. 5 is an exemplary flow chart of method for manufacturing thetransparent shims according to an embodiment of the present disclosure.

FIG. 6 is a simplified perspective view illustrating the mask formanufacturing the transparent shims according to an embodiment of thepresent disclosure.

FIG. 7 is another exemplary flow chart of method for manufacturing thetransparent shims according to an embodiment of the present disclosure.

DESCRIPTION OF THE EMBODIMENTS

Embodiments of the present disclosure will be described in detail belowwith reference to the drawings. Note that similar reference numerals areused to refer to similar elements throughout the drawings, and thusrepetitive descriptions thereof are omitted.

FIG. 1 is a simplified exploded view schematically illustrating a solarcell panel according to an embodiment of the present disclosure. FIG. 2is a simplified perspective view schematically illustrating a solar cellpanel according to an embodiment of the present disclosure.

The solar cell panel 100 includes a solar cell 101 for generatingelectric power from sunlight, a coverglass 102 for covering the solarcell, transparent shims 103 for supporting the coverglass 102 on thesolar cell 101 and an adhesive layer for bonding and encapsulating thesolar cell panel 100. The transparent shims 103 are disposed between thesolar cell 101 and the coverglass 102 at the points where the distancebetween the solar cell 101 and the coverglass 102 needs to becontrolled, and therefore form a space between the solar cell 101 andthe coverglass 102 when they are combined. The adhesive layer fills thespace between the solar cell 101 and the coverglass 102 and has thethickness the same as that of the transparent shims 103. The adhesivelayer can be made of an adhesive (for example, Nusil CV-2500) or anencapsulant (for example, Dow Corning DC93-500). For clarity, theadhesive layer is omitted in FIGS. 1 and 2.

FIG. 3 is a simplified top view schematically illustrating the positionsof the transparent shims relative to the solar cell panel. The solidline shows the outline of a possible solar cell panel 100, and thedotted squares show the outline and possible positions of seventransparent shims 103. These shims of transparent material should beplaced onto the solar cell panel at the points where the bond linethickness needs to be controlled. They can be placed in the corners, oralong the edges, or in the middle, or anywhere that the bond linethickness needs to be controlled. The shape and size of the solar cellpanel, and the size, the shape and the locations of the transparentshims are merely for illustration. In one embodiment, the shims may beapproximately 2 mm×2 mm squares, with the thickness of about 8 mil.

With the above configuration, the thickness of the adhesive layer can becontrolled by the thickness of the transparent shims 103, and it is notnecessary to remove the transparent shims 103 after the adhesive iscured, thereby facilitating the manufacturing of the solar cell panel100.

FIG. 4 is an exemplary flow chart of method for manufacturing the solarcell panel according to an embodiment of the present disclosure.

At step S401, transparent shims 103 with predetermined thickness areprepared. In some embodiments, the transparent shims are prepared inadvance and stored for later use. The process for preparing thetransparent shims will be described in detail latter.

At step S402, the transparent shims 103 are placed on the solar cell 101and/or the coverglass 102, at the points where the distance between thesolar cell 101 and the coverglass 102 needs to be controlled. In someembodiment, the transparent shims are placed on the solar cell, or onthe coverglass, or on both of them. The transparent shims can be wettedwith the adhesive in advance, in order to reduce the formation ofbubbles.

At step S403, an adhesive is dispensed onto the solar cell 101 and/orthe coverglass 102. Based on the requirement on hand, the adhesive canbe dispensed on either one or both of the solar cell 101 and thecoverglass 102, which may or may not have transparent shims disposed onthem yet. The step S403 can be carried out before, after or in parallelwith the step S402. The adhesive can be de-gassed before beingdispensed.

At step S404, the solar cell 101 and/or the coverglass 102 are combined,such that in the combined structure, the transparent shims 103 and theadhesive are sandwiched between the solar cell 101 and the coverglass102 and the thickness of the adhesive layer is the same as that of thetransparent shims 103. In order to ensure the thickness of the adhesivelayer, weight can be placed on top of the combined structure, to ensurethat the adhesive levels out to the desired thickness. In someembodiments, by injecting the adhesive into the space formed by thesolar cell 101, the coverglass 102 and the transparent shims 103, thestep S403 can be carried out after step S404.

At step 405, the adhesive is cured, and then the process ends. Theadhesive can be thermosetting or thermoplastic adhesive. In the case ofthermosetting adhesive, the combined structure is disposed in an ovenfor example at 70° C. for 30 minutes, to allow the adhesive to cure, andthen is removed from the oven. The adhesive can be pre-cured in an ovenfor example at 70° C. for 3 minutes, to the extent that the solar cell101 and the coverglass 102 remain movable with respect to each other,and then the alignment between the solar cell 101 and the coverglass 102can be verified and adjusted.

Based on the above process, the solar cell panel according to theembodiments of the present invention is manufactured.

The transparent shims can be prepared in many ways. Below, the exampleof the process of preparing the transparent shims is described withreference to FIG. 5.

FIG. 5 is an exemplary flow chart of method for manufacturing thetransparent shims. At step S501, spacers with predetermined thicknessare placed on a flat surface at desired place. At step S502, transparentmaterial is dispensed on a flat surface, such that the transparentmaterial may flow around the spacers. At step S503, a flat plate isplaced on top of the transparent material layer, such that the thicknessof the transparent material layer is the same as that of the spacers. Atstep S504, the transparent material layer is cured. At step S505, theflat plate is removed. At step S506, the transparent material layer iscut into the transparent shims, and the process ends. In someembodiments, the flat surface and the flat plate can be microscopeslides. The order of the steps of S501 and S502 can be interchanged, ifit is necessary.

Below, another example of the process of preparing the transparent shimsis described with reference to FIGS. 6 and 7.

FIG. 6 shows the case in which a mask 602 is disposed on a flat surface601. In the mask 602, through holes 603, which define the shape and thethickness of the transparent shims, are formed. FIG. 7 is anotherexemplary flow chart of method for manufacturing the transparent shims.As shown in FIG. 7, the transparent shims are formed in the followingsteps: At step S701, the mask 602 is disposed on the flat surface 601;at step S702, the transparent material is skived onto the mask 602; atstep S703, the transparent material is cured; and at the step S704, themask 602 is removed from the flat surface 601.

It is appreciated that the transparent shims can be prepared in avariety of ways, and the specification merely disclosed some of itsexamples.

The present invention can be embodied in various ways. The abovedescribed orders of the steps for the methods are only intended to beillustrative, and the steps of the methods of the present disclosure arenot limited to the above specifically described orders unless otherwisespecifically stated. Furthermore, those skilled in the art willrecognize that boundaries between the above described operations merelyillustrative. The multiple units/operations may be combined into asingle unit/operation, a single unit/operation may be distributed inadditional units/operations, and units/operations may be operated atleast partially overlapping in time. Moreover, alternative embodimentsmay include multiple instances of a particular unit/operation, and theorder of operations may be altered in various other embodiments.

Note that the embodiments of the present disclosure can be freelycombined with each other without departing from the spirit and scope ofthe invention. It should be understood that the above embodiments can bemodified without departing from the scope and spirit of the presentinvention which are to be defined by the attached claims.

The invention claimed is:
 1. A method for manufacturing a solar cellpanel, comprising the steps of: preparing transparent shims withpredetermined thickness; placing the transparent shims on a solar cellfor generating electric power from sunlight and/or a coverglass forcovering the solar cell, at the points where the distance between thesolar cell and the coverglass needs to be controlled; dispensingadhesive onto the solar cell and/or the coverglass; combining the solarcell and the coverglass, such that the transparent shims and theadhesive is sandwiched between the solar cell and the coverglass and thethickness of the adhesive is the same as that of the transparent shims;and curing the adhesive.
 2. The method of claim 1, wherein before thestep of placing the transparent shims, the transparent shims can bewetted with the adhesive.
 3. The method of claim 1, wherein the step ofdispensing the adhesive can be carried out before, after or in parallelwith the step of placing the transparent shims.
 4. The method of claim1, wherein the step of combining the solar cell and the coverglassfurther comprising placing weight on the combined structure, to levelout the adhesive to the predetermined thickness.
 5. The method of claim1, wherein before the step of curing the adhesive, the method furthercomprising the step of pre-curing the adhesive, and verifying andadjusting the alignment between the solar cell and the coverglass. 6.The method of claim 5, wherein the step of pre-curing the adhesivecomprising curing the adhesive to the extent that the solar cell and thecoverglass remain movable with respect to each other.
 7. The method ofclaim 1, wherein the step of preparing the transparent shims furthercomprising: placing spacers with predetermined thickness on a flatsurface at desired places; dispensing transparent material on the flatsurface; placing a flat plate on top of the transparent material layer,such that the thickness of the transparent material layer is the same asthat of the spacers; curing the transparent material layer; removing theflat plate; and cutting the transparent material layer into thetransparent shims.
 8. The method of claim 7, wherein the flat surfaceand the flat plate are microscope slides.
 9. The method of claim 7,wherein before the step of curing the transparent material layer, theflat plate can be weighted.
 10. The method of claim 1, wherein the stepof preparing the transparent shims further comprising: disposing a maskon a flat surface, wherein the mask has through holes defining the shapeand the thickness of the transparent shims; skiving the transparentmaterial onto the mask; curing the transparent material; and removingthe mask.